US11400524B2 - Drill and method of producing drilled product - Google Patents

Drill and method of producing drilled product Download PDF

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Publication number
US11400524B2
US11400524B2 US16/847,971 US202016847971A US11400524B2 US 11400524 B2 US11400524 B2 US 11400524B2 US 202016847971 A US202016847971 A US 202016847971A US 11400524 B2 US11400524 B2 US 11400524B2
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United States
Prior art keywords
cutting edge
drill
cutting edges
tip
deflection
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US16/847,971
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US20210031277A1 (en
Inventor
Masao Watanabe
Ryohei ONO
Tatsuo Nakahata
Hiroyuki Sugawara
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Subaru Corp
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Subaru Corp
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Assigned to Subaru Corporation reassignment Subaru Corporation ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: Nakahata, Tatsuo, ONO, Ryohei, WATANABE, MASAO, SUGAWARA, HIROYUKI
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
    • B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
    • B26F1/16—Perforating by tool or tools of the drill type
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B51/00—Tools for drilling machines
    • B23B51/009—Stepped drills
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B51/00—Tools for drilling machines
    • B23B51/02—Twist drills
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B51/00—Tools for drilling machines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B51/00—Tools for drilling machines
    • B23B51/0054—Drill guiding devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
    • B23D77/00—Reaming tools
    • B23D77/003—Reaming tools with means for preventing chatter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2226/00—Materials of tools or workpieces not comprising a metal
    • B23B2226/27—Composites
    • B23B2226/275—Carbon fibre reinforced carbon composites
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2250/00—Compensating adverse effects during turning, boring or drilling
    • B23B2250/04—Balancing rotating components
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2251/00—Details of tools for drilling machines
    • B23B2251/04—Angles, e.g. cutting angles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2251/00—Details of tools for drilling machines
    • B23B2251/08—Side or plan views of cutting edges
    • B23B2251/082—Curved cutting edges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2251/00—Details of tools for drilling machines
    • B23B2251/12—Cross sectional views of the cutting edges
    • B23B2251/125—Rounded cutting edges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2251/00—Details of tools for drilling machines
    • B23B2251/14—Configuration of the cutting part, i.e. the main cutting edges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2251/00—Details of tools for drilling machines
    • B23B2251/18—Configuration of the drill point
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2251/00—Details of tools for drilling machines
    • B23B2251/20—Number of cutting edges
    • B23B2251/202—Three cutting edges

Definitions

  • Implementations described herein relate generally to a drill and a method of producing a drilled product.
  • a drill having cutting edges of which point angle and relief angle change continuously toward the maximum diameter position of the cutting edges, and also having a relief angle at the maximum diameter position of the cutting edges, is known as a drill which can drill not only a metal but also an FRP (Fiber Reinforced Plastic), such as GFRP (Glass Fiber Reinforced Plastic) and CFRP (Carbon Fiber Reinforced Plastic), which is also called a composite material, with high quality (for example, refer to Japanese Patent Application Publication JP2008-36759 A, Japanese Patent Application Publication JP2012-135873 A and Japanese Patent Application Publication JP2010-214478 A). Since this drill can machine a hole with remarkably higher quality and have a remarkably extended tool life by improving wear resistance, the drill has become famous with a common name of R-drill (registered trademark).
  • R-drill registered trademark
  • a machine tool such as a drill press, a milling machine or a machining center, of which spindle has high rigidity
  • a hole can be machined with high quality and exchange frequency of the drill caused by wear of the drill can be remarkably reduced.
  • an object of the present invention is to allow drilling a workpiece, made of a composite material, a metal, or the like, with high accuracy, not only in a case where a spindle of a drilling machine has sufficient rigidity but also in a case where drilling is performed by a handheld tool rotating device, and a spindle of a drilling machine has low rigidity or accuracy.
  • a drill includes at least one first cutting edge, at least one second cutting edge and a deflection reducer.
  • the at least one first cutting edge drills a prepared hole to a workpiece.
  • the at least one first cutting edge is formed in a tip side of the drill.
  • the first point angle of the at least one first cutting edge at a tip position is more than 0 degrees and less than 180 degrees.
  • the first point angle continuously or intermittently decreases from the tip side toward a rear end side of the drill.
  • the first relief angle of the at least one first cutting edge continuously or intermittently decreases from the tip side toward the rear end side.
  • the at least one second cutting edge reams the prepared hole.
  • the at least one second cutting edge is formed at a position away in the rear end side from the at least one first cutting edge.
  • the at least one second cutting edge has a second relief angle at a maximum diameter position of the at least one second cutting edge.
  • the deflection reducer reduces deflection of the at least one second cutting edge.
  • the deflection reducer is formed between the at least one first cutting edge and the at least one second cutting edge. The deflection reducer is inserted into the prepared hole.
  • a method of producing a drilled product includes drilling the workpiece with the above-mentioned drill in order to produce the drilled product.
  • FIG. 1 is a front view, of which arrow direction is partially changed, of a drill according to the first implementation of the present invention
  • FIG. 2 is an enlarged left side view of the drill shown in FIG. 1 ;
  • FIG. 3 is an enlarged partial top view of the tip part of the drill shown in FIG. 1 ;
  • FIG. 4 is an enlarged cross-sectional view at the position A-A of the drill shown in FIG. 1 ;
  • FIG. 5 is an enlarged projection view of the cutting edge part on a projection plane parallel to the tool axis for explaining the shape of each cutting edge part shown in FIG. 1 ;
  • FIG. 6 is a partial front view showing an example of the point angles and the relief angles of the tip cutting edge shown in FIG. 1 ;
  • FIG. 7 is a projection view showing an example of the margins formed only within a partial range of the hold part shown in FIG. 1 ;
  • FIG. 8 is a view for explaining an example of a method of drilling a workpiece by attaching the drill to a handheld tool rotating device
  • FIG. 9 is a partial front view of a drill according to the second implementation of the present invention.
  • FIG. 10 is an enlarged partial projection view of reamer edges formed in a drill according to the third implementation of the present invention.
  • FIG. 11 is an enlarged partial projection view showing an example of the reamer edge whose point angle remains 0 degrees without decreasing;
  • FIG. 12 is a projection view showing the first example of a shape of a tip cutting edge formed in a drill according to the fourth implementation of the present invention.
  • FIG. 13 is a projection view showing the second example of a shape of a tip cutting edge formed in a drill according to the fourth implementation of the present invention.
  • FIG. 14 is a projection view showing the third example of a shape of a tip cutting edge formed in a drill according to the fourth implementation of the present invention.
  • FIG. 15 is a projection view showing the fourth example of a shape of a tip cutting edge formed in a drill according to the fourth implementation of the present invention.
  • FIG. 1 is a front view, of which arrow direction is partially changed, of a drill according to the first implementation of the present invention.
  • FIG. 2 is an enlarged left side view of the drill shown in FIG. 1 .
  • FIG. 3 is an enlarged partial top view of the tip part of the drill shown in FIG. 1 .
  • FIG. 4 is an enlarged cross-sectional view at the position A-A of the drill shown in FIG. 1 .
  • a drill 1 is a drilling tool which can drill a workpiece with high quality whether the workpiece is an FRP or a metal. That is, the drill 1 has a shape which can drill not only a metal, such as aluminum and titanium, but also an FRP, such as CFRP and GFRP, and a material obtained by overlapping an FRP with a metal, with high accuracy.
  • the drill 1 has a body 2 , in the tip side in the tool axis AX direction of the drill 1 , and a shank 3 in the rear end side in the tool axis AX direction of the drill 1 .
  • Each of the body 2 and the shank 3 can be made of a typical material, such as a cemented carbide or a tool steel. When the body 2 and the shank 3 are made of a tool steel, it is practical to use a high-speed steel.
  • the shank 3 is a portion for holding the drill 1 with a holder of a handheld tool rotating device, a machine tool or the like.
  • the shank 3 has a special shape which can be easily attached to and detached from a holder in an example shown in FIG. 1
  • the shank 3 may have a desired shape, such as a straight shank or a tapered shank.
  • the body 2 and the shank 3 may consist of an integral material, i.e., the drill 1 may be a solid drill.
  • the drill 1 may be a tipped drill of which the body 2 is inserted into and bonded with the shank 3 as exemplified in FIG. 1 .
  • a cutting edge part 4 for drilling a workpiece is formed at the tip of the body 2 .
  • the cutting edge part 4 has tip cutting edges 5 , which are the first cutting edges, reamer cutting edges 6 , which are the second cutting edges, and a holding part 7 .
  • the tip cutting edges 5 are formed in the tip side of the cutting edge part 4 in the tool axis AX direction.
  • the reamer cutting edges 6 are formed in the rear end side of the cutting edge part 4 in the tool axis AX direction.
  • the reamer cutting edges 6 are formed at positions away, in the rear end side, from the tip cutting edges 5 .
  • the holding part 7 is formed between the tip cutting edges 5 and the reamer cutting edges 6 .
  • Each of the tip cutting edges 5 has a rake face 5 A and a flank 5 B, and a ridgeline formed as a line of intersection of the rake face 5 A and the flank 5 B is a tip of the tip cutting edge 5 .
  • each of the reamer cutting edges 6 also has a rake face 6 A and a flank 6 B, and a ridgeline formed as a line of intersection of the rake face 6 A and the flank 6 B is a tip of the reamer cutting edge 6 .
  • a flank is also called a second face
  • a relief angle which is a clearance angle between a flank and a machined face, is also called a second angle.
  • the number of the tip cutting edges 5 and reamer cutting edges 6 is flexible.
  • the drill 1 exemplified in FIG. 1 to FIG. 4 has three cutting edges consisting of the tip cutting edges 5 and the reamer cutting edges 6 , formed on three lands 9 formed between three grooves 8 respectively, adjacent planar relief faces 9 A, the drill 1 may have two cutting edges, four cutting edges, or five cutting edges. Since the tip cutting edges 5 and the reamer cutting edges 6 are formed in the lands 9 respectively, the number of the tip cutting edges 5 is the same as the number of the reamer cutting edges 6 . That is, the number of the tip cutting edges 5 and the number of the reamer cutting edges 6 are equal to the number of the lands 9 .
  • the drill 1 exemplified in FIG. 1 to FIG. 4 is a straight fluted drill having the untwisted grooves 8
  • the drill 1 may be a twisted drill having the twisted grooves 8 .
  • the groove 8 is a V-groove, i.e., the drill 1 is a straight fluted drill
  • the rigidity of the drill 1 can be increased.
  • the groove 8 is a twisted groove, cutting resistance can be decreased.
  • FIG. 5 is an enlarged projection view of the cutting edge part 4 on a projection plane parallel to the tool axis AX for explaining the shape of each cutting edge part 4 shown in FIG. 1 .
  • FIG. 6 is a partial front view showing an example of the point angles ⁇ and the relief angles ⁇ 1 of the tip cutting edge 5 shown in FIG. 1 .
  • FIG. 5 shows an example of a shape obtained by projecting a passing area of the cutting edge part 4 , on a projection plane parallel to the tool axis AX, in case of rotating the cutting edge part 4 around the tool axis AX. That is, FIG. 5 shows an example of a shape obtained by projecting the cutting edge part 4 , rotated around the tool axis AX, in a direction perpendicular to the tool axis AX.
  • the point angle ⁇ of the tip cutting edges 5 is more than 0° and less than 180° at the tip. Specifically, the point angle ⁇ of the tip cutting edges 5 at the tip of the drill 1 in the tool axis AX direction has a relation of 0° ⁇ 180°. In other words, the drill 1 is not a flat drill or a candle sharpened drill of which point angle is 180°.
  • a point angle of a typical drill is 118° or 120°, and the point angle ⁇ at the tool center position at the tip of the drill 1 can be also determined as an appropriate angle according to cutting conditions, such as a material of a workpiece and the tool diameter D.
  • cutting conditions such as a material of a workpiece and the tool diameter D.
  • each tip cutting edge 5 has such a shape that the point angle ⁇ continuously decreases from the tip side of the tool axis AX direction and the drill 1 toward the rear end side. Therefore, the point angle ⁇ at the tip of the tip cutting edges 5 becomes the maximum value of the point angle ⁇ . Moreover, the diameter of the tip cutting edges 5 continuously increases from the tip side toward the rear end side. Meanwhile, the relief angle ⁇ 1 of each tip cutting edge 5 is also formed so as to continuously decrease from the tip side of the tool axis AX direction and the drill 1 toward the rear end side. Therefore, the relief angle ⁇ 1 of each tip cutting edge 5 also becomes the maximum value at the tip.
  • FIG. 6 shows an example of the point angle ⁇ and the relief angle ⁇ 1 at the position P 1 , the position P 2 and the position P 3 of the tip cutting edge 5 .
  • the point angle ⁇ of the tip cutting edge 5 gradually and continuously decreases so as to be 60°, 30° and 20° between the tip side and the rear end side while the relief angle ⁇ 1 of the tip cutting edge gradually and continuously decreases so as to be 37°, 33° and 31° between the tip side and the rear end side.
  • the relief angle ⁇ 1 at the tip of the tip cutting edge 5 it is desirable to determine the relief angle ⁇ 1 at the tip of the tip cutting edge 5 so that a relation of ⁇ 1 >(180° ⁇ )/2 may be established between the relief angle ⁇ 1 at the tip and the point angle ⁇ at the tip, from a viewpoint of improving cutting conditions. Therefore, when the point angle ⁇ at the tip of the tip cutting edge 5 is 120°, the relief angle ⁇ 1 at the tip of the tip cutting edge 5 can be determined to about 45°, for example.
  • the volume of a workpiece cut by the ridgelines per unit length in the tool axis AX direction can be decreased at a constant rate as the ridgelines are located in the rear side of the tip cutting edges 5 . Therefore, the situation that the wear in posterior portions of the tip cutting edges 5 of which a cutting speed is relatively fast due to different radii of rotation progresses earlier than the wear in anterior portions of the tip cutting edges 5 of which a cutting speed is relatively slow can be avoided, and thereby an effect that the degree of progress of the wear can be made uniform over the whole tip cutting edges 5 can be attained. When the degree of progress of the wear can be made uniform over the whole tip cutting edges 5 , the life of the tip cutting edges 5 can be improved.
  • the shape of the ridgelines of the tip cutting edges 5 on a projection plane can be approximated to a parabola or an ellipse depending on an effect which is thought as important.
  • the shape of the ridgelines of the tip cutting edges 5 on a projection plane may be determined so that a part may have a shape close to an ellipse while another part may have a shape close to a parabola.
  • the point angle ⁇ at the tip of the tip cutting edges 5 becomes 180°. Therefore, it is necessary to determine the shape of the ridgeline of the tip cutting edge 5 so that the point angle ⁇ at the tip of the tip cutting edges 5 may become an angle desirable for drilling a workpiece.
  • the shape of the ridgeline of the tip cutting edge 5 can be determined so that only a portion near the tip of the ridgelines of the tip cutting edges 5 , e.g., the tip side from positions PT 0 shown in FIG. 5 , may be straight lines on a projection plane as exemplified by FIG. 5 , FIG. 6 and the like, for example.
  • the shape of the ridgeline of the tip cutting edge 5 can be determined so that the shape on a projection plane of the ridgelines, in the rear side from the positions PT 0 , following the linear ridgelines at the tip of the tip cutting edges 5 may be a quadratic curve, such as a parabola or an ellipse.
  • the shape of the ridgeline of the tip cutting edge 5 may be determined so that an intersection point of two line-symmetric parabolas derived by offsetting their symmetrical axes in the directions opposite to each other by a same distance from a projected line of the tool axis AX on a projection plane or an intersection point of two line-symmetric ellipses derived by offsetting their long axes in the directions opposite to each other by a same distance from a projected line of the tool axis AX on a projection plane may be a projected point of the tip of the tip cutting edges 5 and a part of the two symmetric parabolas or ellipses in the side close to the projected line of the tool axis AX may be a projected line of the ridgelines of the tip cutting edges 5 .
  • the tip cutting edges 5 of which outline on a projection plane becomes an ellipse two ellipses, a parabola or two parabolas becomes complicated, the ellipse, the two ellipses, the parabola or the two parabolas may be simulated by connecting circles to each other along the ellipse, the two ellipses, the parabola or the two parabolas serving as a reference line RL or reference lines RL.
  • a position PT 0 may be connected with a position PT 1 by a single circle having a same radius
  • the position PT 1 may be connected with a position PT 2 by another single circle having a larger radius
  • the position PT 2 may be connected with a position PT 3 by another single circle having an even larger radius, on a projection plane, for example. That is, determining the shape of the ridgeline of the tip cutting edge 5 so that a projected line of the ridgelines of the tip cutting edges 5 becomes a smooth curve without corners obtained by connecting lines and circles with each other can attain a merit of approximating the projected line of the ridgelines to an ellipse, two ellipses, a parabola or two parabolas while reducing manufacturing costs.
  • a rake angle of each tip cutting edge 5 can be determined according to a material of a workpiece.
  • the rake angle of each tip cutting edge 5 is made 0° i.e., the rake face 5 A of each tip cutting edge 5 is made perpendicular to the cutting face of a workpiece, an effect that delamination is hardly generated at the time of drilling an FRP is attained. This is because the tip cutting edges 5 without a rake angle can finely cut an FRP and reduce open seams of fibers included in the FRP. Therefore, when improving quality of a hole machined on an FRP is considered as important, the rake angle of each tip cutting edge 5 can be made zero.
  • each tip cutting edge 5 has the rake angle which is not zero, drilling conditions for drilling a metal can be made preferable. Therefore, when improving quality of a hole machined on a metal is considered as important, each tip cutting edge 5 may has the rake angle which is not zero. In an illustrated example, the rake angle of each tip cutting edge 5 is 0°. That is, the rake angle is not formed on each tip cutting edge 5 .
  • each reamer cutting edge 6 may also have such a shape that a point angle ⁇ continuously decreases down to 0° and a relief angle ⁇ 2 continuously decreases from the tip side of the tool axis AX direction and the drill 1 toward the rear end side. Therefore, the diameter of the reamer cutting edges 6 also continuously increases from the tip side toward the rear end side. As a result, the point angle ⁇ becomes 0° at the maximum diameter position of the reamer cutting edges 6 . That is, each reamer cutting edge 6 has the non-zero relief angle ⁇ 2 at the maximum diameter position at which the point angle ⁇ becomes 0°.
  • the maximum diameter of the reamer cutting edges 6 in the rear end side is larger than the maximum diameter of the tip cutting edges 5 . Therefore, the maximum diameter of the reamer cutting edges 6 is the tool diameter D of the drill 1 .
  • the maximum diameter of the holding part 7 is made not more than the maximum diameter of the tip cutting edges 5 . Therefore, when a workpiece is machined by the tip cutting edges 5 of which maximum diameter is smaller than the tool diameter D, a prepared hole having a diameter smaller than that of a finished hole to be machined is machined on the workpiece. Accordingly, the tip cutting edges 5 undertake a role of drilling a prepared hole on a workpiece.
  • the holding part 7 When the drill 1 is fed out in the tool axis AX direction while drilling a workpiece, the holding part 7 is inserted into the prepared hole machined by the tip cutting edges 5 since the maximum diameter of the holding part 7 following the tip cutting edges 5 is not more than the maximum diameter of the tip cutting edges 5 . Accordingly, the outer surface having the maximum diameter of the holding part 7 contacts the inner surface of the prepared hole, and thereby the holding part 7 is guided by the prepared hole.
  • the holding part 7 functions as a deflection stopping part which reduces deflection of the reamer cutting edges 6 by being inserted into a prepared hole machined by the tip cutting edges 5 during drilling a workpiece.
  • the holding part 7 it is practical to form the holding part 7 by margins 7 A each having an appropriate width, and not to form any cutting edge in the holding part 7 , from a viewpoint of letting the holding part 7 fulfill a function as a deflection stopper of the reamer cutting edges 6 while avoiding an excessive rise in temperature due to friction between a workpiece and the holding part 7 .
  • the margins 7 A can be formed so that the tip cutting edges 5 are connected with the reamer cutting edges 6 by the margins 7 A respectively.
  • each margin 7 A included in the holding part 7 can be determined to an appropriate width according to the maximum diameter of the tip cutting edges 5 equivalent to the diameter of a prepared hole.
  • the width of each margin 7 A can be determined within a range of 0.1 mm to 1.5 mm, e.g., to about 0.3 mm.
  • the prepared hole is reamed by the reamer cutting edges 6 formed at positions away, in the rear end side, from the tip cutting edges 5 .
  • hole-finish processing for extending the inside diameter of the prepared hole, machined on the workpiece, up to the tool diameter D equivalent to the maximum diameter of the reamer cutting edges 6 can be performed. Thereby, a hole having a diameter corresponding to the tool diameter D can be machined on the workpiece.
  • the drill 1 can be produced by a production method by which a semi-product of the drill 1 whose ridgelines of the reamer cutting edges 6 have been connected with the ridgelines of the tip cutting edges 5 respectively is produced, and subsequently the holding part 7 is formed by cutting or polishing process.
  • steps are generated in the tip side of the reamer cutting edges 6 just by forming the holding part 7 on a semi-product of the drill 1 having cutting edges along the reference line RL consisting of at least one quadratic curve. That is, the tool diameter of the drill 1 increases stepwise at the tip of the reamer cutting edges 6 .
  • steps in the tip side of the reamer cutting edges 6 allowed reaming an FRP under a satisfactory condition while the steps in the tip side of the reamer cutting edges 6 made it difficult to ream a metal under a satisfactory condition.
  • the cutting edges having the constant point angle ⁇ may not be formed in the tip side of the reamer cutting edges 6 so that steps may be formed since the point angle ⁇ of not less than 80° and not more than 100° is not necessarily required for reaming an FRP.
  • the largest point angle ⁇ in the tip side of the reamer cutting edges 6 is the maximum of the point angle ⁇ which decreases continuously.
  • the point angle ⁇ in the rear end side of the reamer cutting edges 6 is made 0° as mentioned above. Since any parabola has no tangent line parallel to the symmetrical axis, it is convenient to determine a shape of the ridgelines of the reamer cutting edges 6 so that a projected line of the ridgeline of the whole reamer cutting edge 6 or a projected line of at least a part of the ridgeline of the reamer cutting edge 6 in the rear end side may become a portion of an ellipse which crosses a short axis, in order to make the point angle ⁇ in the rear end side of the reamer cutting edges 6 be 0°.
  • the respective shapes of the ridgelines of the tip cutting edges 5 and the ridgelines of the reamer cutting edges 6 are determined so that the ridgelines of portions other than the tip, of the tip cutting edges 5 and the ridgelines of the reamer cutting edges 6 on a projection plane parallel to the tool axis AX may lie on circles which simulates the reference line RL consisting of a common ellipse or common ellipses, it becomes possible to reduce labor and costs for manufacturing the drill 1 whose point angle ⁇ in the rear end side of the reamer cutting edges 6 is 0°, by adopting a production method by which a semi-product of the drill 1 whose ridgelines of the tip cutting edges 5 have been connected with the ridgelines of the reamer cutting edges 6 respectively is produced, and subsequently the holding part 7 is formed by cutting work or polishing processing.
  • the maximum relief angle of each of the cutting edges having the constant point angle ⁇ in the tip side of the reamer cutting edges 6 can be made about 11° to 12° while the minimum relief angle ⁇ 2 of each reamer cutting edge 6 at the maximum diameter position of the reamer cutting edges 6 can be made about 10°, for example.
  • a rake angle of each reamer cutting edge 6 can be formed at 0° or an appropriate angle, similarly to the tip cutting edge 5 .
  • a margin 10 can be formed in the rear end side of each reamer cutting edge 6 so that the margin 10 continues from the reamer cutting edge 6 as exemplified by FIG. 1 , FIG. 3 and FIG. 4 . Thereby, the body 2 of the drill 1 can be guided by a hole, which has been finished by the reamer cutting edges 6 , so that deflection of the drill 1 can be reduced.
  • the width of each margin 10 can be determined as an appropriate width according to the tool diameter D. As a concrete example, when the tool diameter D is about 3 mm to 10 mm, the width of each margin 10 can be determined within a range of 0.1 mm to 1.5 mm, e.g., to about 0.3 mm.
  • the margins 7 A in the holding part 7 can be guided by a prepared hole while the margins 10 behind the reamer cutting edges 6 can be guided by a finished hole. That is, deflection of the reamer cutting edges 6 can be suppressed at two positions in the tool axis AX direction which sandwich the reamer cutting edges 6 . As a result, off-centering of the drill 1 in the portion of the reamer cutting edges 6 can be prevented, and thereby a finished hole can be machined with satisfactory quality.
  • the margins 7 A formed in the holding part 7 may have a constant diameter or may have a back taper.
  • the diameter of the holding part 7 is made constant with no back taper, the effect of reducing deflection of the holding part 7 can be maximized since the whole margins 7 A of the holding part 7 are contacted with the inner surface of a prepared hole.
  • an effect of reduction in deflection of the holding part 7 may be improved by omitting a back taper or forming a small back taper on the margins 7 A of the holding part 7 since cutting resistance becomes large and the hard-to-cut material is hard to be welded.
  • the maximum diameter of the holding part 7 When the maximum diameter of the holding part 7 is made too small, the maximum diameter of the tip cutting edges 5 also becomes small, by which the rigidity of the tip cutting edges 5 and the holding part 7 deteriorates, and the amount of depth of cut in finish processing by the reamer cutting edges 6 may be excessive. Accordingly, it is important to secure rigidity of the tip cutting edges 5 and the holding part 7 while making the amount of depth of cut in finish processing by the reamer cutting edges 6 appropriate in order to machine a hole with high quality. As a result of tests, it became clear that it was desirable to make the maximum diameter of the holding part 7 be not less than 0.5 times and not more than 0.9 times of the tool diameter D equivalent to the maximum diameter of the reamer cutting edges 6 .
  • the length Lh of the holding part 7 in the tool axis AX direction can be determined based on the cutting edge length L and the length L 2 appropriate for the reamer cutting edges 6 .
  • the cutting edge length L is expressed as the sum of the length L 1 of the tip cutting edges 5 in the tool axis AX direction, the length Lh of the holding part 7 in the tool axis AX direction, and the length L 2 from the minimum diameter position of the reamer cutting edges 6 to the position, at which the diameter of the reamer cutting edges 6 firstly becomes the maximum, in the tool axis AX direction.
  • a condition for determining shapes of the ridgelines of the tip cutting edges 5 and the reamer cutting edges 6 along a preferable quadratic curve or preferable quadratic curves while determining the point angle ⁇ of the tip cutting edges 5 as an appropriate angle is that the cutting edge length L expressed as the sum of the length L 1 of the tip cutting edges 5 in the tool axis AX direction, the length Lh of the holding part 7 in the tool axis AX direction and the length L 2 from the minimum diameter position of the reamer cutting edges 6 to the position, at which the diameter of the reamer cutting edges 6 firstly becomes the maximum, in the tool axis AX direction is made not less than one time and not more than twice of the maximum diameter of the reamer cutting edges 6 equivalent to the tool diameter D (i.e., 1D ⁇ L ⁇ 2D).
  • the cutting edge length L of the whole drill 1 is determined depending on the tool diameter D. Accordingly, when the maximum diameter of the holding part 7 is determined depending on the tool diameter D, the length L 1 of the tip cutting edges 5 is inevitably determined since the radius of rotation of the tip cutting edges 5 is determined on the basis of the reference line RL which consists of a quadratic curve or quadratic curves, such as a parabola, parabolas, an ellipse or ellipses. Therefore, the length derived by subtracting the length L 1 of the tip cutting edges 5 from the cutting edge length L of the whole drill becomes the sum of the length Lh of the holding part 7 and the length L 2 of the reamer cutting edges 6 . Accordingly, the length derived by subtracting the length L 2 appropriate as the reamer cutting edges 6 can be determined as the length Lh of the holding part 7 .
  • the length of the margins 7 A required to let the holding part 7 fulfill the function to stop deflection may become shorter than the length Lh of the holding part 7 .
  • temperature may increase excessively.
  • a back taper may be formed partially instead of forming a back taper over the whole holding part 7 , or a portion having a constant diameter may be formed partially.
  • a back taper may be formed partially instead of forming a back taper over the whole holding part 7 , or a portion having a constant diameter may be formed partially.
  • the effect of reduction in deflection of the reamer cutting edges 6 can be attained so long as the margins 7 A having the constant maximum diameter or the constant back taper are formed in the range having at least 1 ⁇ 5 length in the tip cutting edge 5 side of the holding part 7 .
  • FIG. 7 is a projection view showing an example of the margins 7 A formed only within a partial range R of the hold part 7 shown in FIG. 1 .
  • the margins 7 A may be formed only in the partial range R of the holding part 7 while the radius of rotation may be decreased in the remaining range. Therefore, when the margins 7 A are formed by polishing, only a certain range R may be polished with high accuracy to form the margins 7 A while a back clearance may be formed in the other range by rough polish processing.
  • FIG. 8 is a view for explaining an example of a method of drilling a workpiece W by attaching the drill 1 to a handheld tool rotating device 20 .
  • a drilled product can be produced as a product or a semi-product by drilling the workpiece W using the drill 1 held by the handheld tool rotating device 20 as shown in FIG. 8 .
  • the drill 1 can be positioned to the workpiece W by attaching a nosepiece 22 having a bushing chip 21 to the tool rotating device 20 while placing a drill plate 23 on the workpiece W.
  • the position and direction of the drill 1 can be positioned by fixing the bushing chip 21 to the drill plate 23 . Then, not only the workpiece W made of a single material, such as an FRP or a metal, but also the workpiece W made of materials, such as overlapped materials of an FRP and a metal, can be drilled using the drill 1 , for example.
  • the tool rotating device 20 in an example shown in FIG. 8 has an automatic feeding function of the drill 1
  • the workpiece W may be drilled by the simple tool rotating device 20 having only a rotation function of the drill 1 .
  • a drilled product may be produced by attaching the drill 1 to a machine tool, such as a drill press or a machining center, or a drilling machine which is not handheld.
  • the drill 1 has the tip cutting edges 5 each having the continuously decreasing point angle ⁇ and relief angle ⁇ 1 , the reamer cutting edges 6 each having the continuously decreasing point angle ⁇ and relief angle ⁇ 2 which does not becomes zero at the maximum diameter position at which the point angle ⁇ becomes 0°, and the hold part 7 consisting of the margins 7 A and the like, for reducing deflection of the reamer cutting edges 6 , between the tip cutting edges 5 and the reamer cutting edges 6 .
  • a method of producing a drilled product is to produce the drilled product using the above-mentioned drill 1 .
  • the drill 1 and the method of producing a drilled product allow reaming of a prepared hole drilled by the tip cutting edges 5 , by the reamer cutting edges 6 while being guided with the holding part 7 by utilizing the prepared hole. That is, vibration of the reamer cutting edges 6 can be suppressed by the holding part 7 . Therefore, a hole having circular cross section can be machined with high quality.
  • this conventional problem is because the coaxiality of the tool axis of the R-drill (registered trademark) cannot be secured, and thereby the R-drill (registered trademark) is deflected when the rigidity or accuracy of a spindle of a drilling device holding the R-drill (registered trademark) is low. Specifically, it is considered that a hole unfavorably becomes a polygon since the cutting edges in the lateral side of the R-drill (registered trademark) contact with the inner surface of the hole while vibrating.
  • the above-mentioned drill 1 derived by improving the R-drill (registered trademark) is used, a finished hole having a circular cross section can be machined by finish processing of a prepared hole by the reamer cutting edges 6 of which deflection has been suppressed by the holding part 7 even when the shape of the cross section of the prepared hole drilled by the tip cutting edges 5 becomes a polygon due to the deflection of the tip cutting edges 5 . Accordingly, a hole can be machined with satisfactory quality even when the number of the tip cutting edges 5 is made not less than three.
  • the above-mentioned drill 1 can machine a hole having a circular cross section.
  • the drill 1 having not less than three cutting edges, which is held by the handheld tool rotating device 20 as exemplified in FIG. 8 , a hole of which cross section has a circular shape can be machined. That is, drilling can be manually performed the drill 1 having not less than three cutting edges.
  • the quality of a hole can be improved since the vibration in the tool diameter D direction can be suppressed compared with the conventional R-drill (registered trademark) having two cutting edges.
  • R-drill registered trademark
  • metal chips are finely cut as a result of restricting the drill 1 to vibrate only in the tool axis AX direction, an effect that clogging with metal chips can be prevented is also obtained. That is, the vibration energy in the tool diameter D direction of the drill 1 can be transformed into the vibration energy in the thrust direction by the holding part 7 , and thereby the energy can be utilized for preventing clogging with metal chips.
  • FIG. 9 is a partial front view of a drill according to the second implementation of the present invention.
  • a drill 1 A in the second implementation shown in FIG. 9 is different from the drill 1 in the first implementation in a point that a portion 6 C having the constant maximum diameter is extended in the rear end side of the reamer cutting edges 6 .
  • Other structures and actions of the drill 1 A in the second implementation are not substantially different from those of the drill 1 in the first implementation. Therefore, only a partial front view of the drill 1 A is shown, and the same signs are attached to the same elements or the corresponding elements while explanation thereof is omitted.
  • the margins 10 in the rear side of the reamer cutting edges 6 may be omitted while the portion 6 C which has the constant maximum diameter can be formed instead.
  • the portion 6 C which has the constant maximum diameter may be formed, and the margins 10 may be formed in the rear side of the portion 6 C.
  • the portion 6 C, of which point angle ⁇ is 0°, having non-zero relief angle ⁇ 2 can be lengthened.
  • FIG. 10 is an enlarged partial projection view of reamer edges formed in a drill according to the third implementation of the present invention.
  • a drill 1 B in the third implementation shown in FIG. 10 is different from each of the drill 1 in the first implementation and the drill 1 A in the second implementation in a point that the projected line of the ridgeline of each reamer cutting edge 6 is not a curved line but a straight line.
  • Other structures and actions of the drill 1 B in the third implementation are not substantially different from those of each of the drill 1 in the first implementation and the drill 1 A in the second implementation. Therefore, only an enlarged partial projection view of the reamer cutting edges 6 is shown, and the same signs are attached to the same elements or the corresponding elements while explanation thereof is omitted.
  • a shape of the ridgeline of each reamer cutting edge 6 may be determined so that the shape of the ridgeline of the reamer cutting edge 6 on a projection plane parallel to the tool axis AX may become line segments connected with each other.
  • each reamer cutting edge 6 can have a shape that the point angle ⁇ intermittently decreases down to 0° from the tip side toward the rear end side while the relief angle ⁇ 2 becomes nonzero at the maximum diameter position where the point angle ⁇ is 0°.
  • FIG. 11 is an enlarged partial projection view showing an example of the reamer cutting edge 6 whose point angle ⁇ remains 0 degrees without decreasing.
  • the point angle ⁇ of the reamer cutting edges 6 may not be decreased intermittently but be limited to 0°. Specifically, so long as the nonzero relief angle ⁇ 2 is formed at the maximum diameter position of the reamer cutting edges 6 at which point angle ⁇ is 0°, other shapes may be omitted or changed. Thereby, a shape of the reamer cutting edge 6 can be simplified further, and labor and costs for manufacturing the drill 1 B can be reduced.
  • the margins 10 may be formed behind the reamer cutting edges 6 , or the portion 6 C of which diameter is constant and maximum may be formed like the second implementation.
  • a shape of the reamer cutting edge 6 can be simplified by making the relief angle ⁇ 2 of the reamer cutting edge 6 decrease intermittently according to the change of the point angle ⁇ , or constant.
  • FIG. 12 is a projection view showing the first example of a shape of a tip cutting edge formed in a drill according to the fourth implementation of the present invention
  • FIG. 13 is a projection view showing the second example of a shape of a tip cutting edge formed in a drill according to the fourth implementation of the present invention
  • FIG. 14 is a projection view showing the third example of a shape of a tip cutting edge formed in a drill according to the fourth implementation of the present invention.
  • FIG. 15 is a projection view showing the fourth example of a shape of a tip cutting edge formed in a drill according to the fourth implementation of the present invention.
  • a drill 1 C in the fourth implementation shown in each of FIG. 12 to FIG. 15 is different from each of the drill 1 , the drill 1 A and the drill 1 B in the other implementations in a point that projected lines of the ridgelines of the tip cutting edges 5 and the reamer cutting edges 6 are not curved lines but line segments connected with each other.
  • Other structures and actions of the drill 1 C in the fourth implementation are not substantially different from those of each of the drill 1 , the drill 1 A and the drill 1 B in the other implementations. Therefore, only a projected view of the cutting edge parts 4 is shown, and the same signs are attached to the same elements or the corresponding elements while explanation thereof is omitted.
  • a projected view of the ridgeline of the reamer cutting edge 6 may also be made connected line segments.
  • the shapes of the respective ridgelines of the tip cutting edges 5 and the reamer cutting edges 6 can be determined so that a projected line of each ridgeline of the tip cutting edges 5 and the reamer cutting edges 6 may be a polygonal line which simulates a quadratic curve, such as a parabola and an ellipse.
  • the drill 1 C can also be classified into a multi-point-angle drill which has the tip cutting edges 5 , having the point angles ⁇ , and the reamer cutting edges 6 , having the single point angle ⁇ of 0° or the point angles ⁇ .
  • the shape of the tip cutting edge 5 can be determined so that a projected line of the ridgelines of the tip cutting edges 5 on a projection plane parallel to the tool axis AX may be a polygonal line, symmetric with respect to a projected line of the tool axis AX as the center line, derived by connecting, with each other, at least six line segments of which respective both ends are on the reference line RL consisting of a single parabola symmetric with respect to the projected line of the tool axis AX as the center line, as exemplified by FIG. 12 .
  • each tip cutting edge 5 is an at least three multi-stage cutting edge having at least three point angles ⁇ 1 , ⁇ 2 and ⁇ 3 .
  • the reference line RL may be replaced from a parabola to an ellipse.
  • the shape of the tip cutting edge 5 can be determined so that a projected line of the ridgelines of the tip cutting edges 5 on a projection plane parallel to the tool axis AX may be a polygonal line, symmetric with respect to a projected line of the tool axis AX as the center line, derived by connecting, with each other, at least eight line segments which are each tangent on the reference line RL consisting of a single parabola symmetric with respect to the projected line of the tool axis AX as the center line, as exemplified by FIG. 13 .
  • each tip cutting edge 5 is an at least four multi-stage cutting edge having at least four point angles ⁇ 1 , ⁇ 2 , ⁇ 3 and ⁇ 4 .
  • the reference line RL may be replaced from a parabola to an ellipse.
  • the shape of the tip cutting edge 5 can be determined so that a projected line of the ridgelines of the tip cutting edges 5 on a projection plane parallel to the tool axis AX may be a polygonal line, symmetric with respect to a projected line of the tool axis AX as the center line, derived by connecting, with each other, at least six line segments of which respective both ends are on the reference line RL consisting of two ellipses, in the side closer to the projected line of the tool axis AX, symmetric with respect to the projected line of the tool axis AX as the center line, as exemplified by FIG. 14 .
  • each tip cutting edge 5 is an at least three multi-stage cutting edge having at least three point angles ⁇ 1 , ⁇ 2 and ⁇ 3 .
  • four point angles ⁇ 1 , ⁇ 2 , ⁇ 3 and ⁇ 4 have been formed.
  • the reference line RL may be replaced from two ellipses to two parabolas.
  • some of line segments composing a polygonal line which is a projected line of the ridgelines of the tip cutting edges 5 on a projection plane parallel to the tool axis AX may be each tangent on the reference line RL, such as a parabola, parabolas, an ellipse, or ellipses while the others may be line segments of which respective both ends are on the reference line RL, as exemplified by FIG. 15 .
  • FIG. 15 In an example shown in FIG.
  • the projected line of the ridgelines forming the maximum point angle ⁇ 1 of the tip cutting edges 5 consists of two symmetric line segments which are each tangent on the reference line RL consisting of a single parabola or ellipse symmetric with respect to the projected line of the tool axis AX as the center line while the projected lines of the ridgelines forming the other point angles ⁇ 2 , ⁇ 3 and ⁇ 4 consist of symmetric line segments of which respective both ends are on the reference line RL.
  • some of line segments composing a projected line of the ridgelines of the tip cutting edges 5 on a projection plane parallel to the tool axis AX may be replaced with curved lines, such as arcs.
  • the tip cutting edge 5 can have a smooth shape without corners. In that case, a risk of causing chipping on the tip cutting edge 5 can be reduced, and thereby a tool life can be lengthened.
  • the shapes of the ridgelines of the tip cutting edges 5 may be determined so that only the projected line of the ridgelines of the tip cutting edges 5 which form the maximum point angle ⁇ at the tip point may consist of line segments while the projected lines of the other ridgelines may consist of curved lines each derived by smoothly connecting arcs, having mutually different radii, with each other.
  • both of the point angle ⁇ and the relief angle ⁇ 1 of the tip cutting edge 5 may be decreased continuously or intermittently from the tip side toward the rear end side.
  • a shape obtained by projecting a passing area of the tip cutting edges 5 , rotating around the tool axis AX, on a projection plane parallel to the tool axis AX can be made a shape, derived by connecting line segments and/or curved lines, such as circular arcs with each other, line symmetric with regard to a projected line of the tool axis AX on the projection plane as the center line, so that the shape of the tip cutting edge 5 can be simplified.
  • the shape of the tip cutting edge 5 can be determined so that positions of at least seven points on curved lines and/or line segments composing a projected line of the ridgelines of the tip cutting edges 5 on a projection plane may be on a quadratic curve or quadratic curves, consisting of a single parabola, two parabolas, a single ellipse or two ellipses, line symmetric with regard to the projected line of the tool axis AX on the projection plane as the center line.
  • the reamer cutting edge 6 can have a shape derived by connecting line segments and/or curved lines, such as arcs, with each other on a projection plane.
  • the shape of the reamer cutting edge 6 can be determined so that a shape obtained by projecting a passing area of the reamer cutting edges 6 , rotated around the tool axis AX, on a projection plane parallel to the tool axis AX may become a shape obtained by connecting line segments and/or curved lines, such as arcs, with each other, and line symmetric with regard to the projected line of the tool axis AX on the projection plane as the center line.
  • the shape of the projected line on a projection plane can be also determined using the reference line consisting of a quadratic curve or quadratic curves same as those for determining the shape of the tip cutting edge 5 .
  • a merit that a production method of forming the holding part 7 on a semi-product of which ridgelines of the tip cutting edges 5 have been connected with those of the reamer cutting edges 6 respectively can be adopted can be obtained.
  • a shape of each ridgeline of the tip cutting edges 5 and the reamer cutting edges 6 can be simplified further, and thereby labor and costs for producing the drill 1 C can be reduced further.

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